U.S. patent application number 10/458655 was filed with the patent office on 2003-12-18 for ignition coil assembly for engine.
Invention is credited to Konishi, Atsuyuki, Tsunenaga, Koji.
Application Number | 20030230294 10/458655 |
Document ID | / |
Family ID | 29727801 |
Filed Date | 2003-12-18 |
United States Patent
Application |
20030230294 |
Kind Code |
A1 |
Tsunenaga, Koji ; et
al. |
December 18, 2003 |
IGNITION COIL ASSEMBLY FOR ENGINE
Abstract
In an ignition coil assembly, a plurality of ignition coils is
arranged to be electrically connected to spark plugs received in
plug holes of an engine. A base cover supports the ignition coils
at corresponding positions, which correspond to positions of the
plug holes, respectively. A top cover covers a top surface of the
base cover. Connecting bolts connects between the top cover and the
base cover. Fastening bolts secures only the base cover to the
engine.
Inventors: |
Tsunenaga, Koji;
(Chiryu-City, JP) ; Konishi, Atsuyuki; (Anjo-City,
JP) |
Correspondence
Address: |
NIXON & VANDERHYE, PC
1100 N GLEBE ROAD
8TH FLOOR
ARLINGTON
VA
22201-4714
US
|
Family ID: |
29727801 |
Appl. No.: |
10/458655 |
Filed: |
June 11, 2003 |
Current U.S.
Class: |
123/635 ;
123/634 |
Current CPC
Class: |
F02P 3/02 20130101; H01T
13/06 20130101; F02P 13/00 20130101 |
Class at
Publication: |
123/635 ;
123/634 |
International
Class: |
F02P 001/00 |
Foreign Application Data
Date |
Code |
Application Number |
Jun 12, 2002 |
JP |
2002-171281 |
Claims
What is claimed is:
1. An ignition coil assembly for an engine, wherein the engine
includes a plurality of plug holes, each of which receives a
corresponding one of a plurality of spark plugs, the ignition coil
assembly comprising: a plurality of ignition coils that are
arranged to be electrically connected to the spark plugs,
respectively; a base cover that supports the ignition coils at
corresponding positions, which correspond to positions of the plug
holes, respectively; a top cover that covers a top surface of the
base cover; a connecting member that connects between the top cover
and the base cover; and a fastening member that secures only the
base cover to the engine.
2. An ignition coil assembly according to claim 1, wherein the
connecting member is a connecting screw member that connects
between the top cover and the base cover.
3. An ignition coil assembly according to claim 2, wherein the top
cover and the base cover are integrally secured to the engine by
the connecting screw member.
4. An ignition coil assembly according to claim 2, wherein: the top
cover includes a top cover through hole, which penetrates through
the top cover and receives the connecting screw member
therethrough, wherein an inner peripheral wall of the top cover
through hole includes female threads; and the connecting screw
member includes a male threaded portion at a distal end of the
connecting screw member, wherein the male threaded portion is
threadably engageable with the female threads of the top cover
through hole.
5. An ignition coil assembly according to claim 2, wherein: the top
cover includes a top cover through hole, which penetrates through
the top cover and receives the connecting screw member
therethrough; the connecting screw member includes: a head that is
located at a proximal end of the connecting screw member; a male
threaded portion that is located at a distal end of the connecting
screw member; and an underhead portion that is located between the
head and the male threaded portion and has an unthreaded smooth
outer surface; a length of the underhead portion is longer than a
length of the top cover through hole; an outer diameter of the
underhead portion is smaller than an inner diameter of the top
cover through hole; and an outer diameter of the male threaded
portion is larger than the inner diameter of the top cover through
hole.
6. An ignition coil assembly according to claim 1, wherein the
connecting member is a spring member that urges the top cover and
the base cover toward each other.
7. An ignition coil assembly according to claim 1, wherein the
fastening member is a fastening screw member that secures the base
cover to the engine.
8. An ignition coil assembly according to claim 7, wherein: the
base cover includes a base cover through hole, which penetrates
through the base cover and receives the fastening screw member
therethrough; the fastening screw member includes: a head that is
located at a proximal end of the fastening screw member; a male
threaded portion that is located at a distal end of the fastening
screw member; and an underhead portion that is located between the
head and the male threaded portion and has an unthreaded smooth
outer surface; and a length of the underhead portion is longer than
a length of the base cover through hole; an outer diameter of the
underhead portion is smaller than an inner diameter of the base
cover through hole; and an outer diameter of the male threaded
portion is larger than the inner diameter of the base cover through
hole.
9. An ignition coil assembly according to claim 1, wherein: the top
cover includes an accommodating through hole, which penetrates
through the top cover and accommodates the fastening member
installed into the base cover; and the accommodating through hole
exposes at least a portion of the fastening member.
10. An ignition coil assembly according to claim 1, wherein: the
base cover includes a flange that projects laterally outwardly; and
the fastening member is connected to the flange to secure the base
cover to the engine.
11. An ignition coil assembly according to claim 1, wherein the
fastening member is a spring member that urges the base cover
against the engine.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is based on and incorporates herein by
reference Japanese Patent Application No. 2002-171281 filed on Jun.
12, 2002.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention generally relates to an ignition coil
device for an engine of, for example, an automobile and more
specifically to an ignition coil assembly that includes a plurality
of ignition coils, which are connected to corresponding spark plugs
securely installed in plug holes of the engine.
[0004] 2. Description of Related Art
[0005] For example, Japanese Unexamined Patent Publication No.
9-250437 discloses an integrated connector block, in which
connectors for supplying electricity to corresponding ignition
coils are integrated. The integrated connector block includes a
connector block main body, which is formed as an elongated body
made of a resin material. Coil connectors are integrally formed in
a lower surface of the connector block main body. Each ignition
coil, which is secured to a corresponding spark plug installed in
an engine, is installed to and is thus engaged with a corresponding
one of the coil connectors in an axial direction of the
corresponding ignition coil, i.e., in an axial direction of the
corresponding spark plug.
[0006] Furthermore, in order to allow installation of the ignition
coils to the plug holes of the engine in a single step, an ignition
coil assembly, which includes a plurality of ignition coils
arranged at predetermined intervals, has been proposed. For
example, as shown in FIG. 12, one such ignition coil assembly 51
includes a base cover 53 and a top cover 54. The base cover 53 is
made of a resin material and has a plurality of receiving through
holes 53a, each of which receives a main body 52b of a
corresponding one of a plurality of ignition coils 52. The ignition
coils 52 are arranged at corresponding positions, which correspond
to positions of plug holes 131 of an engine 130. The top cover 54
is connected to the base cover 53 in such a manner that the top
cover 54 covers a top surface of the base cover 53. The top cover
54 includes a plurality of protrusions 54a. Each protrusion 54a
presses a head 52a of the corresponding ignition coil 52. The
ignition coil assembly 51 is installed to a top surface of the
engine 130 in such a manner that each ignition coil 52 is axially
installed into a corresponding one of the plug holes 131, and
fastening bolts 55 are inserted through corresponding through holes
53d, 54d of the base and top covers 53, 54, which are provided at
longitudinal ends and the center of the base and top covers 53, 54.
Then, the fastening bolts 55 are threadably engaged with
corresponding threaded screw holes 133 of the engine 130. In this
way, the ignition coil assembly 51 is secured to the engine
130.
[0007] However, in the case of the previously proposed ignition
coil assembly 51, when one or some of the ignition coils 52 need to
be replaced after the installation of the ignition coil assembly 51
into the engine 130, it requires tedious and time consuming
reinstallation operation of the ignition coil assembly 51 after
replacement of the ignition coils 52. That is, in the ignition coil
assembly 51, the base cover 53 and the top cover 54 are integrally
secured to the engine 130 by the fastening bolts 55. Thus, when the
fastening bolts 55 are removed, both the top cover 54 and the base
cover 53 are released from the engine 130, and thus the base cover
53 tends to be misaligned relative to the engine 130 (see
positional deviation of the base cover 53 in FIG. 13). At the time
of reinstallation of the ignition coil assembly 51 into the engine
130, the receiving through holes 53a of the base cover 53 need to
be aligned with the plug holes 131 once again, requiring extra time
for the reinstallation.
SUMMARY OF THE INVENTION
[0008] The present invention addresses the above disadvantage.
Thus, it is an objective of the present invention to provide an
ignition coil assembly, which allows removable of only a top part
of the assembly to facilitate replacement of one or more ignition
coils.
[0009] To achieve the objective of the present invention, there is
provided an ignition coil assembly for an engine. The engine
includes a plurality of plug holes, each of which receives a
corresponding one of a plurality of spark plugs. The ignition coil
assembly includes a plurality of ignition coils, abase cover, a top
cover, a connecting member and a fastening member. The ignition
coils are arranged to be electrically connected to the spark plugs,
respectively. The base cover supports the ignition coils at
corresponding positions, which correspond to positions of the plug
holes, respectively. The top cover covers a top surface of the base
cover. The connecting member connects between the top cover and the
base cover. The fastening member secures only the base cover to the
engine.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The invention, together with additional objectives, features
and advantages thereof, will be best understood from the following
description, the appended claims and the accompanying drawings in
which:
[0011] FIG. 1 is a schematic side view of an ignition coil assembly
according to a first embodiment of the present invention;
[0012] FIG. 2 is a plan view of the ignition coil assembly of the
first embodiment;
[0013] FIG. 3 is a schematic side view showing a state after
installation of the ignition coil assembly of the first embodiment
into an engine;
[0014] FIG. 4 is a schematic side view showing a state after
removal of a top cover of the ignition coil assembly of the first
embodiment;
[0015] FIG. 5A is a schematic view showing a connecting bolt
installed into the top cover and a base cover of the ignition coil
assembly of the first embodiment;
[0016] FIG. 5B is a schematic view showing a partially removed
state of the connecting bolt of the first embodiment;
[0017] FIG. 6 is a schematic side view of an ignition coil assembly
according to a second embodiment of the present invention;
[0018] FIG. 7 is a schematic side view showing a partially
installed state of the ignition coil assembly of the second
embodiment;
[0019] FIG. 8A is a schematic view showing a connecting bolt
installed into a through hole of a top cover and a through hole of
a base cover of the ignition coil assembly of the second embodiment
and is threadably engaged with a threaded screw of the engine;
[0020] FIG. 8B is a schematic view showing a state where the
connecting bolt of the second embodiment is threadably engaged with
the through hole of the base cover;
[0021] FIG. 8C is a schematic view showing a state where the
connecting bolt of the second embodiment is engaged with an
peripheral edge of the through hole of the top cover;
[0022] FIG. 9 is a plan view of an ignition coil assembly according
to a third embodiment of the present invention;
[0023] FIG. 10A is a plan view of an ignition coil assembly
according to a fourth embodiment of the present invention;
[0024] FIG. 10B is a cross sectional view along line XB-XB in FIG.
10A;
[0025] FIG. 11 is a schematic side view showing a modification of
the ignition coil assembly;
[0026] FIG. 12 is a schematic side view of a previously proposed
ignition coil assembly; and
[0027] FIG. 13 is a schematic side view showing a state after
removal of a top cover and fastening bolts of the previously
proposed ignition coil assembly.
DETAILED DESCRIPTION OF THE INVENTION
[0028] Various embodiments of the present invention will be
described with reference to the accompanying drawings.
[0029] (First Embodiment)
[0030] An ignition coil assembly 1 according to a first embodiment
of the present invention will be described with reference to FIGS.
1 to 5.
[0031] The ignition coil assembly 1 is for an automobile engine and
includes a plurality of ignition coils 2, which are arranged at
predetermined intervals and are axially connected to corresponding
spark plugs securely received in plug holes of the engine.
[0032] That is, as shown in FIGS. 1 to 4, the ignition coil
assembly 1 includes the ignition coils 2, a base cover 3, a top
cover 4, two fastening bolts 5 and three connecting bolts 6. The
base cover 3 supports the ignition coils 2 at predetermined
intervals. The top cover 4 is arranged to cover a top surface of
the base cover 3. The fastening bolts 5 serve as fastening members
(or fastening screws) that secure only the base cover 3 to the
engine 30. The connecting bolts 6 serve as connecting members (or
connecting screws) that connect between the base cover 3 and the
top cover 4. It should be understood that the ignition coil
assembly 1 shown in FIG. 1 is for a four cylinder engine and thus
includes four ignition coils 2.
[0033] Each ignition coil 2 is formed as a stick shaped component
that has a case, which is made of a dielectric resin material and
receives an electric circuit for generating high voltage to be
supplied to the corresponding spark plug 32. As shown in FIG. 1,
each ignition coil 2 includes a head 2a, a cylindrical main body 2b
and a tubular plug cap 2c. The head 2a is arranged at the top end
of the ignition coil 2. The cylindrical main body 2b extends
downwardly from the head 2a. The tubular plug cap 2c is connected
to the lower end of the main body 2b.
[0034] The head 2a is formed as a generally cubic body. A size of
the head 2a, i.e., a diameter of the circumcircle, which passes
through all vertices of the head 2a in a plane that is
perpendicular to the axis of the ignition coil 2, is greater than
the inner diameter of a corresponding one of the plug holes 31 of
the engine 30. A connector (not shown) projects laterally from one
side of the head 2a of each ignition coil 2. The connector of each
ignition coil 2 is connected to a connector of a cord electrically
connected to a battery (not shown) to allow supply of electric
current to the ignition coil 2.
[0035] The cylindrical main body 2b has the outer diameter smaller
than the size of the head 2a and is inserted into the corresponding
plug hole 31. Thus, each ignition coil 2 is installed to the base
cover 3 such that the main body 2b of the ignition coil 2 is
inserted through a corresponding one of receiving through holes 3a
of the base cover 3, and the head 2a is placed over the top surface
of the base cover 3 around the corresponding one of the receiving
through holes 3a.
[0036] The tubular plug cap 2c is formed as a tubular body made of
a resilient material, such as a rubber material. When the ignition
coil 2 is inserted into the corresponding plug hole 31, an inner
peripheral surface of the plug cap 2c of the ignition coil 2
receives a top end of the corresponding spark plug 32 such that the
ignition coil 2 and the spark plug 32 are connected to each other.
Each of the plug cap 2c and the main body 2b has a corresponding
internal engaging structure that allows secure engagement between
the plug cap 2c and the main body 2b at the inside thereof. The
plug cap 2c and the main body 2b are securely engaged with each
other in a manner that prevents disengagement of the plug cap 2c
from the main body 2b even when the plug cap 2c is axially pulled
in a direction away from the main body 2b.
[0037] The base cover 3 is an elongated plate like body made of,
for example, a dielectric resin material. The receiving through
holes 3a of the base cover 3 are arranged at corresponding
positions that correspond to positions of the plug holes 31 of the
engine 30 and receive the main body 2b of the corresponding
ignition coil 2. The inner diameter .phi.A of each receiving
through hole 3a is greater than the outer diameter .phi.B of the
corresponding main body 2b such that the main body 2b is loosely
received through the receiving through hole 3a. Thus, when the main
body 2b is received through the receiving through hole 3a, there is
provided play (or a gap), which corresponds to .phi.A-.phi.B. As a
result, each ignition coil 2 can slide within the range of
.phi.A-.phi.B in an imaginary plane that is perpendicular to the
axis of the ignition coil 2. It is desirable that the amount of
.phi.A-.phi.B is kept within the tolerance of the corresponding
plug hole pitches (intervals of the plug holes).
[0038] Two base cover through holes 3b are provided in the base
cover 3. One of the base cover through holes 3b is positioned
between one of the opposed longitudinal ends of the base cover 3
and the center of the base cover 3, and the other one of the base
cover through holes 3b is positioned between the other one of the
opposed longitudinal ends of the base cover 3 and the center of the
base cover 3. The positions of the base cover through holes 3b
correspond to positions of threaded screw holes 33 of the engine
30. Female threads, which are threadably engageable with male
threads of a male threaded portion 5b of the corresponding
fastening bolt 5, are formed along an inner peripheral surface of
each base cover through hole 3b.
[0039] Flanges 3c are provided at the longitudinal ends of the base
cover 3, and three screw holes 3d for threadably engaging with the
connecting bolts 6 are provided in the flanges 3c and the center of
the base cover 3.
[0040] Similar to the base cover 3, the top cover 4 is an elongated
plate like body made of, for example, a dielectric resin material.
A plurality of coil stop protrusions 4a is provided in a lower
surface of the top cover 4 to protrude downward. The positions of
the coil stop protrusions 4a correspond to the positions of the
ignition coils 2.
[0041] Two accommodating through holes 4b are provided in the top
cover 4. One of the through holes 4b is positioned between one of
the opposed longitudinal ends of the top cover 4 and the center of
the top cover 4, and the other one of the through holes 4b is
positioned between the other one of the opposed longitudinal ends
of the top cover 4 and the center of the top cover 4. The inner
diameter of each through hole 4b is larger than a size of a head 5a
of the corresponding fastening bolt 5, i.e., an diameter of the
circumcircle, which passes through all vertices of the head 5a in a
plane that is perpendicular to the axis of the bolt 5. Thus, the
head 5a of each bolt 5 is exposed outside the corresponding through
hole 4b. As a result, tightening and loosing of each bolt 5 can be
relatively easily performed while the top cover 4 is secured to the
base cover 3.
[0042] Flanges 4c are provided at the longitudinal ends of the top
cover 4, and three top cover through holes 4d are provided in the
flanges 4c and the center of the top cover 4. The top cover through
holes 4d are formed coaxially with the corresponding screw holes
3d. Female threads, which are threadably engageable with male
threads of a male threaded portion 6b of the corresponding
connecting bolt 6, are formed along an inner peripheral surface of
each top cover through hole 4d.
[0043] Each fastening bolt 5 is formed as a hexagonal bolt and
includes the head 5a, the male threaded portion 5b and an underhead
portion 5c. The head 5a is provided at a proximal end of the bolt
5. The male threaded portion 5b is provided at a distal end of the
bolt 5 and is provided with the male threads, which are threadably
engageable with the female threads of the corresponding base cover
through hole 3b. The underhead portion 5c is provided between the
head 5a and the male threaded portion 5b and has an unthreaded
smooth outer surface.
[0044] Each connecting bolt 6 is formed as a hexagonal bolt and
includes a head 6a, the male threaded portion 6b and an underhead
portion 6c. The head 6a is provided at a proximal end of the
connecting bolt 6. The male threaded portion 6b is provided at a
distal end of the connecting bolt 6 and has the male threads, which
are threadably engageable with the female threads of the
corresponding top cover through hole 4c. The underhead portion 6c
is provided between the head 6a and the male threaded portion 6b
and has an unthreaded smooth outer surface.
[0045] The top cover 4 is installed such that the top cover 4
covers the base cover 3. Furthermore, each connecting bolt 6 is
received through the corresponding top cover through hole 4d, and
the male threaded portion 6b of the connecting bolt 6 is threadably
engaged with the female threads of the corresponding screw hole 3d
of the base cover 3. In this way, the top cover 4 and the base
cover 3 are connected to each other.
[0046] Furthermore, after the top cover 4 and the base cover 3 are
connected together by the connecting bolts 6, each fastening bolt 5
is received through the corresponding base cover through hole 3b,
and the male threaded portion 5b at the distal end of the fastening
bolt 5 is threadably engaged with the female threads of the
corresponding screw hole 33 of the engine 30. In this way, only the
base cover 3 is directly secured to the engine 30.
[0047] Installation procedure of the ignition coil assembly 1 into
the engine 30 will be described with reference to FIGS. 1 to 3.
[0048] First, as shown in FIGS. 1 and 2, after the top cover 4 and
the base cover 3 are connected together by the connecting bolts 6,
the ignition coil assembly 1 is placed over the engine 30 such that
the ignition coils 2 are aligned with the plug holes 31 of the
engine 30.
[0049] Then, the ignition coil assembly 1 is lowered such that each
ignition coil 2 is axially inserted into the corresponding plug
hole 31, and the base cover 3 is placed on the top surface of the
engine 30. Furthermore, the top surface of the top cover 4 is urged
downward, so that the inner peripheral surface of the plug cap 2c
of each ignition coil 2 is engaged with the top end of the
corresponding spark plug 32. In this way, the ignition coil 2 and
the spark plug 32 are connected to each other. Even if
manufacturing error in the plug hole pitches of the plug holes 31
occurs, each ignition coil 2 can be easily and reliably secured to
the corresponding plug hole 31 in the following manner. That is, as
described above, the main body 2b of each ignition coil 2 is
loosely received in the corresponding receiving through hole 3a of
the base cover 3, and the top cover 4 and the base cover 3 are
temporarily fastened to the engine 30 by the fastening bolts 5, so
that each ignition coil 2 can be inserted into the corresponding
plug hole 31 and can abut against the inner peripheral surface of
the corresponding plug hole 31 to achieve slide adjustment of the
position of each ignition coil 2 in the plane that is perpendicular
to the axis of the ignition coil 2. Each coil stop protrusion 4a
located in the lower surface of the top cover 4 is downwardly
pressed against the head 2a of the corresponding ignition coil 2 to
secure the same.
[0050] Thereafter, each fastening bolt 5, which is exposed in the
corresponding top cover through hole 4b is rotated clockwise (i.
e., rotated in the tightening direction) with a known bolt
tightening tool, so that the male threaded portion 5b of the
fastening bolt 5 is threaded into the corresponding screw hole 33
of the engine 30, and thereby the top cover 4 is secured to the
engine 30 together with the base cover 3.
[0051] Finally, the connector of each ignition coil 2 located at
the back side of the head 2a is connected to the corresponding
connector of the cord connected to the battery (not shown). In this
way, installation of the ignition coil assembly 1 is completed.
[0052] Next, the procedure for replacing one or more ignition coils
2 after completion of the installation of the ignition coil
assembly 1 into the engine 30 will be described.
[0053] First, each connecting bolt 6 is rotated counterclockwise
(i. e., rotated in the loosening direction) to loosen the
connecting bolt 6, so that the engagement between the top cover 4
and the base cover 3 is released. Next, the top cover 4 is lifted,
and thus the top cover 4 is removed from the base cover 3 (see FIG.
4). At this stage, when each connecting bolt 6 is further rotated
counterclockwise, the male threaded portion 6b is threadably
engaged with the female threads of the corresponding top cover
through hole 4d, so that detachment of the connecting bolt 6 from
the top cover 4 is advantageously limited (see FIG. 5). The base
cover 3 is kept secured to the engine 30 by the fastening bolts 5.
Furthermore, since each ignition coil 2 is connected to the
corresponding spark plug 32 through the plug cap 2c, the head 2a of
each ignition coil 2 is remained on the top surface of the base
cover 3 around the corresponding receiving through hole 3a.
[0054] Thereafter, the ignition coil(s) 2, which requires
replacement, examination or the like, is removed from the
corresponding plug hole(s) 31. After completion of the
corresponding work, such as the replacement of the corresponding
ignition coil 2, the top cover 4 is placed over the base cover 3 to
cover the base cover 3. Then, each connecting bolt 6 is aligned
with the corresponding base cover screw hole 3d and is rotated
clockwise (i.e., rotated in the tightening direction) by the known
bolt tightening tool, so that each connection bolt 6 is threaded
into the corresponding base cover screw hole 3d. In this way, the
top cover 4 is connected to the base cover 3.
[0055] Upon completion of the above procedure, the work, such as
the replacement of the corresponding ignition coil 2, is
completed.
[0056] At the time of removing the entire ignition coil assembly 1
from the engine 30, the following procedure is performed. First,
each fastening bolt 5 is rotated counterclockwise (i.e., rotated in
the loosening direction) with use of the known bolt removing tool
to loosen each fastening bolt 5. Then, the base cover 3 is lifted
away from the engine 30 to integrally remove the base cover 3 and
the top cover 4, which are connected together by the connecting
bolts 6. At this time, since the head 2a of each ignition coil 2 is
placed on the top surface of the base cover 3 around the
corresponding receiving through hole 3a, each ignition coil 2 is
removed together with the base cover 3 and the top cover 4 from the
engine 30. Furthermore, as described above, the female threads are
formed in each base cover through hole 3b, so that when the base
cover 3 is removed from the engine 30, the male threaded portion 5b
of each fastening bolt 5 is threadably engaged with the female
threads of the corresponding base cover through hole 3b. Thus,
detachment of each fastening bolt 5 from the base cover 3 is
limited (this is achieved with the structure similar to the
structure of the connecting bolt 6 shown in FIG. 5).
[0057] The ignition coils 2 are integrated by the base cover 3 and
the top cover 4 and are arranged at the intervals, which correspond
to the intervals of the plug holes 31 of the engine 30, in such a
manner that each ignition coil 2 is oriented in the axial direction
of the corresponding plug hole 31. Thus, the ignition coils 2 can
be installed into the engine 30 at once in a single step. As a
result, an installation time period required to install the
ignition coils 2 is reduced in comparison to the case where the
ignition coils 2 are installed one by one.
[0058] Furthermore, at the time of replacing one or more ignition
coils 2, it is possible to remove only the top cover 4 while the
base cover 3 is kept secured to the engine 30. Thus, the
corresponding ignition coil 2, which requires examination or
replacement, can be easily removed. Also, it is not required to
reposition the base cover 3 and each ignition coil 2 relative to
the engine 30 to install them to the engine 30. Thus, the
corresponding work, such as replacement of the corresponding
ignition coil 2, can be simply and quickly performed.
[0059] Even when the manufacturing error in the plug hole pitches
occur, each ignition coil 2 can be easily and reliably instilled
into the corresponding plug hole 31 because of the structure that
allows positioning of each ignition coil 2 relative to the top
cover 4 and the base cover 3 in the plane that is perpendicular to
the axis of the ignition coil 2.
[0060] (Second Embodiment)
[0061] A second embodiment of the present invention will be
described with reference to FIGS. 6 to 8. The components similar to
those discussed with reference to the first embodiment will be
indicated by the same numerals and will not be described for the
sake of simplicity.
[0062] In the second embodiment, at the time of installation to the
engine 30, the top cover 4 and the base cover 3 are integrally
secured to the engine 30 by bolts used to connect the top cover 4
and the base cover 3 together.
[0063] That is, as shown in FIG. 6, in the base cover 3 of an
ignition coil assembly 11 of the second embodiment, three base
cover through holes 3e are provided in place of the screw holes 3d
of the first embodiment, and female threads are formed in an inner
peripheral surface of each base cover through hole 3e. Furthermore,
three threaded screw holes 34 are formed in the engine 30 at
positions, which correspond to the positions of the base cover
through holes 3e.
[0064] Before installation of the ignition coil assembly 11 into
the engine 30, three connecting bolts 16 are received through the
top cover through holes 4d, respectively, and a male threaded
portion 16b of each connecting bolt 16 is threadably engaged with
the female threads of the corresponding base cover through hole 3e.
In this way, the top cover 4 and the base cover 3 are connected
together, as shown in FIG. 6.
[0065] Then, as shown in FIG. 7, each base cover through hole 3e of
the base cover 3 is aligned with the corresponding screw hole 34 of
the engine 30, and the base cover 3 is placed on the top surface of
the engine 30. Then, each connecting bolt 16 is rotated clockwise
(i.e., rotated in the tightening direction), so that each
connecting bolt 16 is threaded into the screw hole 34 of the engine
30. Thus, the base cover 3 is secured to the engine 30 with the
connecting bolts 5, and, at the same tine, the top cover 4 and the
base cover 3 are integrally secured to the engine 30 by the
connecting bolts 16. As a result, the ignition coil assembly 11 is
more tightly secured to the engine 30 in comparison to the ignition
coil assembly 1 of the first embodiment.
[0066] Next, a detachment preventing structure for preventing
detachment of each connecting bolt 16 from the ignition coil
assembly 11 will be described with reference to FIGS. 8A-8C. FIG.
8A shows a state where each connecting bolt 16 is threadably
engaged with the corresponding screw 34 of the engine 30, so that
the top cover 4 and the base cover 3 are integrally secured to the
engine 30. FIG. 8B shows a state where each connecting bolt 16 is
threadably engaged with the corresponding base cover through hole
3e to connect between the top cover 4 and the base cover 3. FIG. 8C
shows a state where the upper end of the male threaded portion 16b
of each connecting bolt 16 is engaged with the lower end peripheral
edge of the top cover through hole 4d.
[0067] As shown in FIGS. 8A-8C, the male threaded portion 16b and
the underhead portion 16c of the connecting bolt 16 are formed to
satisfy the following relationship:
.phi.E<.phi.C<.phi.D
[0068] where .phi.E is the outer diameter of the underhead portion
16c, .phi.C is the inner diameter of the top cover through hole 4d,
and .phi.D is the outer diameter of the male threaded portion 16b.
The axial length L1 of the underhead portion 16c is selected to be
longer than the sum of the length L2 of the base cover through hole
3e and the length L3 of the top cover through hole 4d.
[0069] As mentioned above, the outer diameter .phi.D of the male
threaded portion 16b is larger than the inner diameter .phi.C of
the top cover through hole 4d, so that the upper end of the male
threaded portion 16b of the connecting bolt 16 engages the lower
end peripheral edge of the top cover through hole 4d to prevent
detachment of the connecting bolt 16.
[0070] Each fastening bolt 5 can have the structure similar to the
above described detachment preventing structure of the connecting
bolt 16 if it is appropriate.
[0071] (Third Embodiment)
[0072] A third embodiment of the present invention will be
described with reference to FIG. 9.
[0073] An ignition coil assembly 21 of the third embodiment is
constructed to be secured to the engine 30 at the outer periphery
of the base cover 3.
[0074] That is, the base cover 3 of the ignition coil assembly 21
has four flanges 3f. Two of the flanges 3f project laterally
outwardly from one lateral side of the base cover 3, and the other
two of flanges 3f project laterally outwardly from the other
lateral side of the base cover 3. Each flange 3f has a base cover
through hole 3b, which penetrates through the flange 3f and
receives a corresponding fastening bolt 5 in a manner similar to
the first embodiment.
[0075] The fastening bolt 5 is received through the base cover
through hole 3b of the corresponding flange 3f and is threadably
engaged with a corresponding screw hole 33 of the engine 30 to
secure only the base cover 3 to the engine 30.
[0076] In the present embodiment, the fastening bolts 5 are
provided around the outer peripheral of the base cover 3, so that
there is no need to provide the accommodating through holes 4d in
the top cover 4 to expose the corresponding fastening bolts 5
secured to the base cover 3, as in the case of the first
embodiment.
[0077] (Fourth Embodiment)
[0078] A fourth embodiment of the present invention will be
described with reference to FIGS. 10A and 10B.
[0079] An ignition coil assembly 31 of the fourth embodiment is
constructed to be secured to the engine 30 by securing the base
cover to the engine 30 through use of spring members 35 without
using the fastening bolts.
[0080] That is, as shown in FIGS. 10A and 10B, the top surface of
the engine 30 is provide with flanges (or protrusions) 30a, and the
base cover 3 of the ignition coil assembly 31 has flanges 3g at
positions that correspond to the positions of the flanges 30a of
the engine 30. A distal end of each flange 30a of the engine 30
projects downward, and a distal end of each flange 3g of the base
cover 3 projects upward, as shown in FIG. 10B.
[0081] A mouth of each spring member 35 made of a C-shaped plate
spring is press fitted against the corresponding flange 30a of the
engine 30 and the corresponding flange 3g of the base cover 3, so
that the distal end of the flange 30a of the engine 30 and the
distal end of the flange 3g of the base cover 3 are connected
together by the spring member 35. In this way, only the base cover
3 is urged against and is secured to the engine 30. Furthermore, by
removing each spring member 35 from the corresponding flange 30a of
the engine 30 and the corresponding flange 3g of the base cover 3,
the base cover 3 can be released from the engine 30.
[0082] It should be noted that the present invention is not limited
to the above embodiments, and the above embodiments can be modified
in any appropriate manner without departing from the scope of the
invention.
[0083] For example, in the fourth embodiment, the base cover 3 is
secured to the engine 30 by the spring members 35. Alternatively,
as shown in FIG. 11, in an ignition coil assembly 41, which is a
modification of the ignition coil assembly 1 of the first
embodiment, the base cover 3 and the top cover 4 can be connected
together by two spring members 36, each of which is made of a
C-shaped plate spring and urges the base cover 3 and the top cover
4 toward each other. Each spring member 36 is similar to the spring
members 35 shown in FIGS. 10A and 10B and is engaged with the base
cover 3 and the top cover 4 in a manner similar to that of the
spring member 35 discussed above. That is, the base cover 3 has two
flanges 3h at the longitudinal ends of the base cover 3, and a
distal end of each flange 3h projects downward. The top cover 4 has
two flanges 4e at the longitudinal ends of the top cover 4, and a
distal end of each flange 4e projects upward. A mouth of each
spring member 36 is press fitted against the corresponding flange
3h of the base cover 3 and the corresponding flange 4e of the top
cover 4, so that the distal end of the flange 3h of the base cover
3 and the distal end of the flange 4e of the top cover 4 are
connected together by the spring member 36.
[0084] In the above embodiments, the fastening bolts 5, the spring
members 35 and the connecting bolts 6, 16 are depicted for the
illustrative purpose. Thus, any known fastening means and/or
connecting means can be used in place of them.
[0085] Additional advantages and modifications will readily occur
to those skilled in the art. The invention in its broader terms is
therefore not limited to the specific details, representative
apparatus, and illustrative examples shown and described.
* * * * *